We remove the generator for repair or replacement, as well as when repairing the power plant
Removing the generator
Generator for engines ZMZ-402 and ZMZ-4021:
1. Disconnect the wire from the "negative" terminal of the battery.
- 2. Disconnect the block 1 from the brush holder and, having unscrewed the bolt 2, disconnect the wires from the generator.
- 3. Remove the belt.
- 4. Loosen the adjusting bolt
- 5. Finally unscrew the two bolts of the lower mounting of the generator, while holding the generator
Remove generator
Generator disassembly
1. Unscrew the two screws 1 and remove the brush holder 2.
Unscrew nut 3 on the "positive" terminal of the generator and disconnect the capacitor wire.
Remove the plastic insulating sleeve 4.
Remove screw 5 and remove capacitor 6.
- 2. Unscrew the four tie bolts 1 and remove the cover 2 on the side of the slip rings together with the stator.
- 3. Unscrew three nuts 1, disconnect the stator terminals 2 from the rectifier unit and remove the stator 3.
- 4. Unscrew the three screws 1 securing the rectifier unit to the cover and remove the "positive" terminal 2 of the generator, while removing the plastic insulating sleeve from the terminal on the reverse side of the rectifier unit.
Remove the rectifier unit 3.
- 5. Loosen nut 1, remove pulley 2 and fan 3
- 6. Remove the key 1 from the armature shaft.
Press the armature shaft 2 out of the cover bearing 3 on the drive side.
- 7. Loosen the four screws 1 and remove the bearing cover 2.
Remove the bearing, in case of difficulty, you can knock out the bearing with light blows of the hammer through the drift.
Checking and inspecting the generator
- 1. Check the brushes.
- 2. Check slip rings. If they have scuffs, marks, scratches, wear marks from brushes, etc., the rings must be sanded.
- 3. The remaining checks are carried out in the same way as the generator 9422.3701.
Building a generator
The generator is assembled in the reverse order of disassembly.
When installing the rectifier unit, pay attention to the fact that a plastic insulating sleeve must be put on the "positive" terminal under the unit.
Generator installation
Install the generator in the reverse order of removal. After installation, adjust the belt tension
Checking and replacing the generator brushes
Disconnect the wire from the "negative" terminal of the battery.
Disconnect the block 1 with the wire from the brush holder terminal.
Unscrew the two screws 2 and remove the brush holder 3 from the generator.
Check the ease of movement of the brushes in the brush holder.
If the brushes are stuck, remove the two fixing screws and remove the brush holder cover.
Clean the brushes and clean the holes in the brush holder.
If you cannot achieve the desired result, replace the brush holder assembly or brushes.
Brushes with chips, cracks or other defects should also be replaced.
Check the protrusion of the brushes from the brush holder.
If the value "a" of the protrusion of the brushes in the free state is less than 8 mm, replace the brush holder assembly or the brushes.